TPSi OBUKA

TPSi
OBUKA
Fronius International GmbH

Perfect Welding
Generalni zastupnik za BiH:
AX-Soling doo
88340 Grude
NOVI KOMPAKTNI SUSTAV
TPS 270i C Pulse
TPS 320i C Pulse
Fronius International GmbH / Perfect Welding , Team Training / APP034 TPS/i

NOVI DVOKOMPONENTNI SUSTAV
TPS 320i / 400i / 500i / 600i
TPS 320i / 400i / 500i / 600i PULSE
TPS 400i LSC Adv

/ 06.2014
Izvor Napajanja
Koncept i Inovacije
4 Fronius International GmbH / Perfect Welding , Team Training / APP034 TPS/i / 06.2014
KONFIGURACIJA – KOMPAKTNI IZVOR NAPAJANJA
Gorionik
TPS 320i C
Hladnjak CU 1100i
Kolica TU CAR 4

/ 06.2014
KONFIGURACIJA – DVOKOMPONENTNI SUSTAV
Dodavač žice WF 25i
Gorionik & Šlauf paket
TPS 500i
Hladnjak CU 1400i PRO /MC
Kolica 5000

/ 06.2014
INOVACIJE
FSC
7“ Displey na dodir
Priključak hladnjaka
SpeedNet
24V EC Pumpa
Provodna matica za
bužire
Novi priključak za
masu
MultiLock
7

/ 06.2014
MATRICA POVEZIVANJA
Ethernet
SpeedNet
SpeedNet (u FSC-u)
RS 485 (LocalNet)
SpeedNet
2-Wire Bus
Fronius International GmbH / Perfect Welding / TPS/i

Dodavač Žice
Inačice dodavača žice
/ WF15i
/ WF15i n.S. (no Spool)
/ 42V AC Motor
/ Vodom hlađen pogon
/ WF25i
/ 42V DC Motor
/ Zrakom hlađen pogon
/ WF30i
/ 42V AC Motor
/ Vodom hlađen pogon
/ WF25i Case D200 or Case D300
Dodavač žice – dodatna oprema
I-kit Kranski-transport VR 5000

/ 4,100,660
/ 4,100,660,U
I-kit Aluminijski bočni klizač VR 5000

/ 4,100,671
/ 4,100,671,U
I-kit mjerač protoka plina VR 5000

/ 4,100,672
/ 4,100,672,U
Kolica Trabant VR 5000

/ 4,077,004 (2 Upravljiva kotača)
/ 4,077,008 (4 Upravljiva kotača)
11
Nosač pogona & Pogonski kotači
/ Aluminijski nosač pogona
/ Samo-otvarajući pritiskajući mehanizam
/ Jedna ručica za podešavanje pritiska
/ Pogonski kotači u boji za različite promjere žice
/ U-žljeb sa 4 kontaktne točke

/ Otporan na trošenje – HRC 60
/ Kuglični ležaj
Hladnjak
Inačice hladnjaka
/ CU 1100i
/ CU 1100i / 460V US Market
/ CU 1100i / MV
/ CU 1100i Basic no control
/ CU 1100i Basic / 460V no control / US Market
/ CU 1400i Pro
/ CU 1400i Pro / MC Flow-Thermo+Level Sensor
/ CU 800i
/ CU 800i Basic (no control)
/ CU 800i Basic / 460V (no control / US Market)
/ CU 800i / 460V (US Market)
Cooling Units CU1100i – CU1400i Pro MC
1100 … Performanse hlađenja [W]

1400 … Performanse hlađenja [W]
CU ...... CoolingUnit
i .......... Intelligent Revolution Za tipove:
TPS 320i, TPS 400i & TPS 500i
Basic .. Bez prekida – Kontinuiran rad TPS 320i C
Pro .... Professional (EC Pumpe)
za više-stupanjski rad
MV .... Multivoltage 200-230V i 400 – 480V
460V … za 460V mains (USA)
MC .... MultiControl (Praćenje Protoka, Temperature
i razine)
Inovacija: Konektor hladnjaka
/ Brzo i jednostavno spajanje hladnjaka

/ Ukopčaj i upali
Upravljanje
Korisničko sučelje
/ 7“ Touch-Display
/ Trenutne vrijednosti
/ Odabir parametara zavarivanja
/ USB ulaz
/ Update
/ Backup/Restore
/ Otključavanje novih opcija
/ Potenciometar
/ Upravljanje Karuselom
/ Pritiskom se odabire prikazani prozor
/ Promjena parametara - rotiranjem
/ Pritiskom se potvrđuju odabrani
parametri
/ Gumb za izlazak Žice i Plina
Područja
Status ploča
Lijeva Desna bočna

bočna traka traka
Glavni Menu sa karuselom
Svojstva u
zavarivanju
OSJETI RAZLIKU – NOVI PROCESI
LSC – Low Spatter Control
STANDARD / Nova “stabilizator penetracije” funkcija
koristi se za luk u spreju kada se mijenja visina žice;
funkcija može biti uključena ili isključena
/ Uobičajena Fronius kvaliteta za
kratkospojeni i luk u spreju / LSC root karakteristika:
Visoki tlak luka za bolje formiranje korijena u
/ Optimalan za većinu materijala i mješavina
prinudnim položajima
plinova
/ LSC universal karakteristika:
Kontrola prekida kratkog spoja sa lakšim
uspostavljanjem luka i brzom regulacijom
PULSE PMC – Pulse Multi Control

/ Općepoznata kvaliteta Fronius / Povećana stabilnost procesa
impulsa / Optimirana karakteristika impulsa i poboljšano
/ Optimalan za većinu materijala i paljenje luka
mješavina plinova / Veća stabilnost sa manjim unosom energije (brzina
zavarivanja i visina luka)
/ Stabilizator penetracije za ravnomjernije mješanje
materijala
21 Fronius International GmbH / Intelligent Revolution / 20.08.3013

LSC KRATAK OPIS
/ LSC znači Low Spatter Control

/ LSC je napravljen za luk kratkog spoja koji oblikovan tako da:
minimalizira prskotine
poveća stabilnost luka
poveća kvalitetu spoja
smanji vrijeme obuke zavarivača
poveća iznos depozita
zadrži konstantnu penetraciju
22
Fronius International GmbH / Martin Willinger / Fundamentals of the LSC Process / May 2014 - v02
OSNOVE LUKA KRATKOG SPOJA
/ Svojstva luka kratkog spoja: manja kontrola i više prskotina.
23
OSNOVE LSC UNIVERSAL (Adv.)
Preklopni spoj Kutni spoj Popuna & Završni prolaz
/ Jednolilčna karakteristika luka / Visoka stabilnost luka / Velika količina depozita

/ Minimum prskotina / Manje prskotina / Odlična penetracija zahvaljujući
/ Izvrsno kvašenje / Velika količina depozita stabilizatoru penetracije
24
USPOREDBA LSC VS LUK KRATKOG SPOJA
25
OSNOVE LSC ROOT (Adv.)
/ Root LSC (and LSC Adv.): lako upravljanje luka, velike sile odvajanja, odlično ojačanje korijena, minimum prskotina.
26
1. Korak
/ Glavna struja formira kapljicu
/ Kraj žice se topi i oblikuje veliku
kapljicu.
2. Korak
/ Velika kapljica dodiruje talinu čime
premošćuje udaljenost do taline
/ Jačina struje se smanjuje na
minimum kako bi se izbjegle
prskotine i vrtloženje luka.
27
3. Korak
/ Struja raste do odvajanja kapljice.
4. Korak
/ Prijenos kapljice se odvija pri najmanjoj
struji.
/ Udaljenost od žice do taline svladana.
/ Manjom strujom izbjegnuto progaranje i
ulazak žice u talinu.
28
5. Korak
/ Struja se penje na najvišu vrijednost i
potiskuje talinu.
/ Rezultat je odlično ojačanje korijena
29
USPOREDBA LSC VS LUK KRATKOG SPOJA
/ wfs: 6m/min (235ipm) / wfs: 6m/min (235ipm)

/ I: 140 amps / I: 128 amps
/ U: 18,6 V / U: 18,2 V
/ Čelik 5mm (1/5”) / Čelik 5mm (1/5”)
30
PRIMJENE LSC (ADV.) UNIVERSAL
IndustriJE
/ Namještaj
/ Cijevi
/ Automobilska industrija
Vrste zavarenih spojeva

/ Kutni
/ Preklopni
/ Sučeoni PA (1G)
/ Rubni
31
APPLICATIONS FOR LSC (ADV.) BRAZE
Outside Corner Braze Joint Butt Braze Joint Lap Braze Joint
1mm 1mm 1mm
/ Filler alloy: CuSi3 (ER CuSi-A) / Filler alloy: CuSi3 (ER CuSi-A) / Filler alloy: CuSi3 (ER CuSi-A)
/ Wire diameter: 1,0mm (0.040”) / Wire diameter: 1,0mm (0.040”) / Wire diameter: 1,0mm (0.040”)
/ Shielding gas: Argon 4.6 / Shielding gas: Argon 4.6 / Shielding gas: Argon 4.6
/ wfs: 3,6m/min / wfs: 3,6m/min (140 ipm) / wfs: 6,0m/min (235 ipm)
/ I: 70 Amp. / I: 72 Amp. / I: 120 Amp.
/ U: 13 Volt / U: 12,8 Volt / U: 13,5 Volt
/ Zinc thickness: 4-5µm / Zinc thickness: 4-5µm / Zinc thickness: 4-5µm
/ Electro galvanized / Electro galvanized / Electro galvanized
32
KONTRTOLA DINAMIKE U OJAČANJU KORIJENA
Postavka Dynamic u minus Postavka Dynamic na 0 Postavka Dynamic u plus
/ Povećan tlak luka / Srednji tlak luka / Manji tlak luka

/ Veće ojačanje korijena / Za korijen na cijevima / Za poziciju PA (1G)
/ Pogodan za uske zazore / Pozicije PA (1G) do 2h / Dobar efekt kvašenja
/ Vertikalno dole i nadglavno / Dobar efekt kvašenja
33
KORIJENI PROLAZ U USPOREDBI VERTIKALNO GORE I
VERTIKALNO DOLJE
Stick (MMA) (rutil/E6013) TIG (GTAW) Short Arc Vertical Down Short Arc Vertical Up LSC Adv. Vertical Down
/ U:22,82V / I:83,44 / U:9,3V / I:123 / U:16,65 / I:140,7 / U:15,68 / I:101,7 / U:14,69 / I:145,8
/ Vs: 9cm/min / Vs: 5,5cm/min / Vs:25cm/min / Vs: 12cm/min / Vs: 25cm/min
/ E: 1,26kJ/mm / E: 1,24kJ/mm / E: 0,55kJ/mm / E: 0,80kJ/mm / E: 0,51kJ/mm
/ wfs: 3,6m/min / wfs: 2,5m/min / wfs: 3,6m/min
/ Position: gore / Position: gore / Position: Dolje / Position: gore / Position: dolje
/ Electrode Ø: 2,5mm / Filler Ø: 2,0mm / Wire Ø: 1,2mm / Wire Ø: 1,2mm / Wire Ø: 1,2mm
/ Gas: Argon / Gas: Ar+ 18%CO2 / Gas: Ar+ 18%CO2 / Gas: Ar+ 18%CO2
/ Gas flow: 10l/min / Gas flow: 12l/min / Gas flow: 12l/min / Gas flow: 10l/min
34
USPOREDBA PROCESA
Stick LSC TIG LSC
Heat input (kJ/mm) 1,26 0,51 59% decrease + Heat input (kJ/mm) 1,24 0,51 59% decrease +
Vs (cm/min) 9 25 2,7 times faster + Vs (cm/min) 5,5 25 4,5 times faster +
Deposition rate (kg/h) 1,9 + Deposition rate (kg/h) 1,9 +
Gas consumption (l/m) 40 - Gas consumption (l/m) 181 40 78% less +
Slag removal Yes No + Slag removal No No =
Electrode changeover Often Rare + Electrode changeover Often Rare +
Penetration perfect perfect = Penetration perfect perfect =
Root reinforcement Yes Yes = Root reinforcement Yes Yes =
Operation / handling Difficult Easy + Operation / handling Difficult Easy +
Short arc vertical down LSC Short arc vertical up LSC

Heat input (kJ/mm) 0,55 0,51 = Heat input (kJ/mm) 0,80 0,51 37% less +
Vs (cm/min) 25 25 = Vs (cm/min) 12 25 2 times faster +
Deposition rate (kg/h) 1,9 1,9 = Deposition rate (kg/h) 1,3 1,9 46% more +
Gas consumption (l/m) 48 40 17% less + Gas consumption (l/m) 100 40 60% less +
Slag removal No No = Slag removal No No =
Electrode changeover Rare Rare = Electrode changeover Rare Rare =
Penetration Lack of fusing perfect + Penetration Good perfect +
Root reinforcement No Yes + Root reinforcement Minimum to 0 Yes +
Operation / handling Difficult Easy + Operation / handling Difficult Easy +
35
USPOREDBA PROCESA
36
USPOREDBA PROCESA
37
EXAMPLE PLATFORMS:
38
OFFSHORE PEDESTAL CURRENT OPERATION
Pipe manual root pass joint Outside Stick Root Pass Inside Stick “wash out” pass
/Lorem ipsumare
Pipe joints dolor situp
lined amet, consec root
for manual / Outside root pass done with Stick. /Lorem
The inside
ipsumpass
doloris sit
necessary
amet, consec
to wash
tetuer
pass adipiscing
welding. elit. Aenean commodo / Long grinding time tetuer
out the
adipiscing
root passelit.
to Aenean
avoid lack
commodo
of fusion.
/ligula
Fill &eget
Capdolor. /ligula eget dolor.
Necessary for X-ray quality
passes are done with / Low deposition rate
Submerged Arc Welding Process /Aenean
Low duty cycle Cum sociis natoque
Aenean massa. Cum sociis natoque / High H2 content massa.
pena tibus etmagnis dis parturient /pena
Low tibus etmagnis
deposition rate dis parturient
/ Slag removal
montes, nasc etur ridiculus mus. Donec montes, nasc etur ridiculus mus. Donec
quam felis, ultricies nec, pellentesque eu, / More training time /quam
Slag felis,
removal necessary
ultricies nec, pellentesque eu,
pretium quis, sem. /pretium
Long grinding
quis, sem.time
39
OFFSHORE PEDESTAL SOLUTION
Pipe manual root pass joint Outside LSC Root Pass No “wash out” pass necessary
/Lorem ipsumare
Pipe joints dolor situp
lined amet, consec root
for manual / Outside root pass done with TPS320i /Lorem
Theinside
No inside
ipsum
wash
pass
dolor
out
is sit
necessary
pass
amet,
necessary.
consec
to wash
tetuer
pass adipiscing
welding. elit. Aenean commodo LSC /tetuer
out the
adipiscing
root passelit.
No undercuts to Aenean
avoid lack
commodo
of fusion.
/ligula
Fill &eget
Capdolor. /ligula
/ Short grinding time High eget
Necessary dolor.
qualityfor
weld.
X-ray quality
passes are done with
Submerged Arc Welding Process / High deposition rate /Aenean
Low duty cycle Cum sociis natoque
Aenean massa. Cum sociis natoque massa.
pena tibus etmagnis dis parturient / Low H2 content /pena
Low tibus etmagnis
deposition rate dis parturient
montes, nasc etur ridiculus mus. Donec montes, nasc etur ridiculus mus. Donec
/ No slag removal /quam
Slag felis,
removal necessary
quam felis, ultricies nec, pellentesque eu, ultricies nec, pellentesque eu,
pretium quis, sem. / Less training time /pretium
Long grinding
quis, sem.time
40
SKLONOST NASTANKU H2 PUKOTINA
45
ml of diffusible H2 per 100g of deposited weld metal
40
35
30
25
20 maximum allowance of H2
15
10
Hydrogen level of different welding processes
5
/ Cellulose Electrodes (e.g. E6010): 40-60 ml/100g weld metal
0 / Rutil Electrodes (e.g. E6013): 10-15 ml/100g weld metal
X60 X80 X100 X120 / Flux cored wire: 5-20ml/100g weld metal
Pipe steel grade
/ TIG: less than 4ml/100g weld metal
/ MAG (e.g. LSC) less than 4ml/100g weld metal
41
LSC ROOT VS. CELULOZNA ELEKTRODA
Solid Wire Ø 1,2mm (0.045”) Cellulose Electrode Ø 3,25mm (E6010)
/ Parameters: / Parameters:
wfs: 3,6 m/min I: ~ 82 Amp.
I: ~ 130 Amp. U: ~ 32 V
U: ~ 16,5 V Dyn: 50
Dyn: - 5.0 Travel Speed: ~ 17 cm/min
Travel Speed: ~ 17 cm/min E: ~ 0,9 kJ/mm
E: ~ 0,75 kJ/mm
/ Minimum prskotina / Više prskotina
/ Nema troske / Troska
/ Manje brušenja / Visok sadržaj vodika
42
PRIMJENE LSC ROOT (ADV.)
Industries
/ Pipe Industry
/ Pipeline
/ Boiler & Pressure vessels
/ Steel construction
/ Open root welding

/ Mild Steel
/ Fine grain steel
/ Stainless steel
43
UTJECAJ INDUKTIVITETA
/ Nepravilno postavljanje kabela
/ Pravilno postavljanje kabela
Magnetska polja se poništavaju
44
UTJECAJ INDUKTIVITETA
Proces Induktivitet Stabilnost luka

LSC Nizak odlična
LSC Visok dobra
LSC Vrlo visok prskotine
LSC Adv. Nizak i vrlo visok odlična
/ Postavljanje kabela direktno utječe na induktivitet
45
Usporedba konfiguracija zračno hlađenje opcije - LSC / LSC
Advanced CE
/ Konfiguracija LSC CE / Konfiguracija LSC Advance CE

Part Number Description Quantity Part Number Description Quantity
4,075,174 TPS 400i 400V /CE 1 4,075,175 TPS 400i LSC ADV 400V /CE 1
4,066,014 WP LSC 4,077,002 Carriage PickUp 5000 1
4,077,002 Carriage PickUp 5000 1 4,100,613 I-kit turning pintle mounting VR 5000 1
4,100,613 I-kit turning pintle mounting VR 5000 1 4,049,031 WF 25i/4R/G/FSC 1
4,049,031 WF 25i/4R/G/FSC 1 44,0001,1407 Feeder roll U1,2mm (0.045”) 4
44,0001,1407 Feeder roll U1,2mm (0.045”) 4 4,047,834 HP 95i CON/G/1,2m 1
4,047,834 HP 95i CON/G/1,2m 1 43,0004,0581 Ground cable 95mm² 4m 1
43,0004,0581 Ground cable 95mm² 4m 1 4,035,932 MTG 320i/FSC/JM/4,5m/45°/LED 1
4,035,932 MTG 320i/FSC/JM/4,5m/45°/LED 1 44,0350,5120 BK Fe Ø1,2/G/W/5m 1
44,0350,5120 BK Fe Ø1,2/G/W/5m 1 42,700,001 Service PAT Inverter 1
42,700,001 Service PAT Inverter 1
46
Configuration Comparisons Air Cooled - LSC / LSC Advanced
CE/UL/CSA Version 400-460V
/ LSC Configuration 400-460V / LSC Advanced Configuration 400-460V

4,075,174,800 TPS 400i /nc 400-460V 1 4,075,175,800 TPS 400i LSC ADV /nc 400-460V 1
47
CE/UL/CSA Version Multivoltage (200-460V)
/ LSC Configuration MV / LSC Advanced Configuration MV

4,075,174,830 TPS 400i /MV/nc 1 4,075,175,830 TPS 400i LSC ADV /MV/nc 1
48
UL/CSA Version 600V
/ LSC Configuration 600V / LSC Advanced Configuration 600V

4,075,174,800 TPS 400i /600V/nc 1 4,075,175,970 TPS 400i LSC ADV /600V/nc 1
49
OSNOVE PMC PROCESA
PMC - PULSE MULTI CONTROL - PREGLED
Jednolična Penetracija
Više opcija za fino podešavanje parametara
Stabilizator penetracije održava penetraciju
Parametri početka i kraja zavarivanja se mogu još preciznije konstantnom i uz promjenu udaljenosti dizne od
ugađati. metalne kupke. Od pomoći pri zavarivanju uskih i
nepristupačnih žljebova.
Povećana Stabilnost Luka

Zahvaljujući Speed Net komunikaciji i postignutoj Visokoj stabilnosti luka
omogućene su veće brzine zavarivanja s minimum do 0 greški u zavaru.
VELIKA STABILNOST LUKA = VISOKE PERFORMANSE ZAVARIVANJA
Univerzalna primjena
PMC se može koristiti sa različitim dodatnim Jednostavno postavljanje
materijalima, npr. Nisko i Visoko legirani
čelici, Aluminij i njegove legure, itd. Također, Parametri kao što je Stabilnost luka
primjena je ista za razne promjere žica i pomažu zavarivačima u postavljanju
smjese plinova. parametara kojima će dobiti savršen
zavar pri svakom prolazu.
51
Fronius International GmbH / first name last name / Titel of presentation / xx.xx.20xx - v02
STABILIZATOR PENETRACIJE U POZICIJI VERTIKALNO PREMA GORE
Stabilizator penetracije na OFF Stabilizator penetracije na ON

/ Nejednolika penetracija / Jednolika penetration
A B A A B A
Position A (short CTWD) Position B (long CTWD) Position A (short CTWD) Position B (long CTWD)
wfs = = wfs ↓ ↑
Amp. ↑ ↓ Amp. = =
Volts = = Volts ↓ ↑
Penetration ↑ ↓ Penetration = =
52
OPIS: STABILIZATOR PENETRACIJE “OFF”
/ A change in the contact tube distance (CTWD) causes a
current change in characteristic lines with constant voltage
characteristics (CV)
/ The penetration depth is mainly determined by the welding
current
/ Example: Macro: “P-Stab” = Off / 0 m/min
Pos.2: CTWD = 20mm Pos 1.: CTWD = 10mm
vd = 21 m/min vd = 21 m/min
Penetration = 3.4mm Penetration = 4.2 mm
2 1
PGM2851 / „Steel dynamic PMC“ / G3Si1 ø1,0mm / 82% Ar 18%CO2 / CTWD 10mm bis 20mm / Schweißgeschw. 100cm/min
53
Constant WFS 11,9m/min  Welding current variable
54
PRINCIPLE: PENETRATION STABILIZER “ON”
/ When changing the contact tube distance (CTWD) a
constant current behavior (CC) can only be obtained by
a wire feed adjustment
/ The maximum feed change is determined by the setting
of the Penetration Stabilizer
/ Example: Macro: “P-Stab” = 5 m/min
Pos.2: CTWD = 20mm Pos 1.: CTWD = 10mm
2 1
2 1
PGM2851 / „Steel dynamic PMC“ / G3Si1 ø1,0mm / 82% Ar 18%CO2 / CTWD 10mm bis 20mm / Schweißgeschw.100cm/min
55
Constant Current 320A  WFS variable
56
COMPARISON: 10mm FILLET WELD VERTICAL UP
(PF/3Fu) a7 / Z3/8”
Conventional MAG FCAW LSC + Penetration stabilizer LSC + Penetration stabilizer
/ Wire size: 1,2mm (0.045”) / Wire size: 1,2mm (0.045“) / Wire size: 1,2mm (0.045”) / Wire size: 1,0mm (0.040”)
/ Filler metal: / Filler metal: / Filler metal: / Filler metal:
G3Si1 (ER70S-6) E81T-Ni (rutil) G3Si1 (ER70S-6) G3Si1 (ER70S-6)
/ U:18,4 / I:183 / U:22,7 / I:152 / U:18 / I:171 / U:19,8 / I:154
/ vs: 10cm/min / vs: 10cm/min / vs: 10cm/min / vs: 10cm/min
/ E: 2,02 kJ/mm / E: 2,07 kJ/mm / E: 1,84 kJ/mm / E: 1,77 kJ/mm
/ wfs: 5,2m/min (205ipm) / wfs: 8m/min (315ipm) / wfs: 5,2m/min (205ipm) / wfs: 7,5m/min (295ipm)
/ Gas: Ar+18%CO2 / Gas: Ar+18%CO2 / Gas: Ar+18%CO2 / Gas: Ar+18%CO2
/ Gas flow: 12l/min / Gas flow: 15l/min / Gas flow: 10l/min / Gas flow: 10l/min
57
PRINCIPLE PULSED ARC
I/U
Arc length changes can appear during welding due to surface variations, increased travel speed
58
Fronius International GmbH / Martin Willinger / Fundamentals of the PMC Process Sales Meeting NA 2014 / Aug. 2014 - v01
PRINCIPLE PMC ARC + ARC LENGTH STABILIZER
I/U
PMC adds dedicated short circuits to increase travel speed, penetration and arc stability.
59
ARC LENGTH STABILIZER
/ Regardless of the welding position, the weld geometry or interference, the properties of the
controlled, faulted arc remain the same
AL-Stab = 0 AL-Stab = 0.5 AL-Stab = 2
60
PULSE VS PMC USING ARC LENGTH STABILIZER
61
EXAMPLE: ARC LENGTH – STABILIZER
/ Adjusted process characteristics are maintained
Optimized for butt-weld Arc changed by changing weld
AL-corr. = -3 joint
AL-stab = 0 AL-corr. = -3
AL-stab = 0
Initial set:
AL-Corr. = 0
AL-Stab = 0
Result using Stabilizer Result using Stabilizer

AL-corr. = 0 AL-corr. = 0
AL-Stab = 0.5 AL-Stab = 0.5
62
ARC LENGTH STABILIZER SETTINGS
Arc length stabilizer set to 0.0 Arc length stabilizer set to 0.5 Arc length stabilizer set to 2.0
/ No dedicated short circuits / Low amount of dedicated short circuits / Large amount of dedicated short
/ Good arc stability / Increased arc stability circuits
/ Low travel speed / Increased travel speed / Increased arc stability
/ Applications: / Applications: / High travel speeds
- Cap passes - Root and fill passes / Applications:
- 1F / PA position - Fillet welds - Lap joints
- …….. - Out of position welds - Vertical down welds
- ……. - ……..
63
COMBINATION: “AL-STAB” + “PENETRATION-STABILIZER”
/ Constant short arc + a constant Penetration
/ Stabilizes the welding process when disturbances occur, the
welding seam position or shape or the contact tube distance
changes
/ Example: Macro: G3Si1 ø1.0mm, 18% CO2 Rest Ar
P-Stab = 5m/min, AL-Stab = 0.5
Pos.2: CTWD = 10mm Pos 1.: CTWD = 10 mm
2 1
PGM2851 / „Steel dynamic PMC“ / G3Si1 ø1,0mm / 82% Ar 18%CO2 / CTWD 10mm bis 20mm / Schweißgeschw. 100cm/min
64
PROCESS COMPARISON 10MM SAND BLASTED STEEL
Pulse PMC Universal PMC PCS
5mm 5mm 5mm
/ Synergic line: 2785 / Synergic line: 2850 / Synergic line: 2890

/ Wfs: 11m/min (435ipm) / Wfs: 11m/min (435ipm) / Wfs: 11m/min (435ipm)
/ I (rms): 345,7 Amp. / I (rms): 329,5 Amp. / I (rms): 321,2 Amp.
/ U (rms): 29,25 Volt / U (rms): 25,42 Volt / U (rms): 24,71 Volt
/ vs: 50cm/min (20ipm) / vs: 50cm/min (20ipm) / vs: 50cm/min (20ipm)
/ Real Energy: 1,152 kJ/mm / Real Energy: 0,924 kJ/mm / Real Energy: 0,924 kJ/mm
/ Arc length stabilizer. 1.0 / Arc length stabilizer: 1.0
65
Std. universal Std. Dynamic LSC Univ.
5mm 5mm 5mm

/ Wfs: 11m/min (435ipm) / Wfs: 11m/min (435ipm) / Wfs: 11m/min (435ipm)
66
5mm 5mm 5mm

/ Wfs: 12,2m/min (480ipm) / Wfs: 12,2m/min (480ipm) / Wfs: 12,2m/min (480ipm)
67
Std. Universal Std. Dynamic LSC Univ.
5mm 5mm 5mm

/ Wfs: 12,2m/min (480ipm) / Wfs: 12,2m/min (480ipm) / Wfs: 12,2m/min (480ipm)
/ I (rms): 310 Amp. / I (rms): 359,9 Amp. / I (rms): 299,8 Amp.
68
PROCESS COMPARISON 5MM HOT ROLLED STEEL
5mm 5mm 5mm

/ wfs: 9,4m/min (370ipm) / wfs: 9,4m/min (370ipm) / wfs: 9,4m/min (370ipm)
/ vs: 55cm/min (21.5ipm) / vs: 55cm/min (21.5ipm) / vs: 55cm/min (21.5ipm)
69
PROCESS COMPARISON 5MM HOT ROLLED STEEL
5mm 5mm 5mm

/ I (rms): 256,5 Amp. / I (rms): 253 Amp. / I (rms): 244,7 Amp.
70

/ I (rms): 314,1 Amp. / I (rms): 302 Amp. / I (rms): 297,3 Amp.
71

72
PROCESS HEAT INPUT (“REAL ENERGY”) COMPARISON
1,4
1,2
1
0,8 10mm sand blasted
kJ/mm

5mm mill scale
0,2
0
Pulse PMC PMC Std. Std. LSC
Univ. PCS Univ. Dyn. Univ.
73
CTWD HEAT INPUT COMPARISON
/ PMC achieves the lowest and most consistence heat input
1,6
1,4
1,2
1
CTWD 10mm
0,8
CTWD 15mm
0,6 CTWD 20mm
0,4
0,2
0
Std. Univ. LSC Univ. Pulse PMC Univ.
/ Same wire feed speed was used for all processes (10m/min)
/ Penetration stabilizer was set to max. on PMC and LSC
/ Arc length stabilizer was used on PMC
74
RESULT: SMOOTH WELD APPEARANCE, LESS STRESS
UTILIZING ARC LENGTH STABILIZER
Standard (CV) Pulsed Arc PMC
/ Stress raiser / Stress raiser / Smooth weld appearance

/ Increased stress / Increased stress / Less stress in the weld
/ Decreased travel speed / Decreased travel speed / High travel speed possible
/ Good penetration profile / Good penetration profile / Excellent penetration profile
/ Smooth lines of force
75
Fronius International GmbH / Product Launch Perfect Welding 2015
OUTSTANDING PERFORMANCE USING PMC
/ Standard / Std. Dynamic / LSC Univ. / Pulse / PMC-PCS / PMC

3mm
8mm
10mm
76
AGENDA
/ PMC Heat Input Comparison

 Different transfer modes
/ Fume Generation During Welding

 Comparing CV, FCW with PMC
/ Welding of Galvanized Steel
77
PMC FUME GENERATION COMPARISON
1,4mm (0.052“) FCW Std. (CV) 1,4mm (0.052“) Solid Std. (CV) 1,4mm (0.052“) PMC
/Lorem
Filler ipsum
alloy:dolor
E71 sit1Mamet, consec
H8 (rutil) /Lorem
Filler ipsum
alloy:dolor sit amet,
ER70S-3 consec
/ G2Si1 /Lorem
Filler ipsum
alloy:dolor sit amet,
ER70S-3 consec
/ G2Si1
tetuer adipiscing elit. Aenean commodo tetuer adipiscing elit. Aenean commodo tetuer adipiscing elit. Aenean commodo
/ligula
Synergic line: 2739 (Std.)
eget dolor.
/ligula
Synergic line: 2711 (Std.)
eget dolor.
/ligula
Synergic line: 2904 (PMC)
eget dolor.
/ Gas: 82%Ar + 18%CO2 / Gas: 82%Ar + 18%CO2 / Gas: 82%Ar + 18%CO2
/Aenean massa. Cum
wfs: 17m/min sociis natoque
(670ipm) /Aenean massa. Cum
(510ipm) /Aenean massa. Cum
(510ipm)
pena tibus etmagnis dis parturient pena tibus etmagnis dis parturient pena tibus etmagnis dis parturient
/montes,
I (rms):nasc
432,8eturAridiculus mus. Donec /montes,
I (rms):nasc
429,5
eturAridiculus mus. Donec /montes,
I (rms):nasc
426,2eturAridiculus mus. Donec
/quam felis, 33,17
V (rms): ultriciesVnec, pellentesque eu, /quam felis, 34,2
V (rms): ultricies
V nec, pellentesque eu, /quam felis, 32V
V (rms): ultricies nec, pellentesque eu,
pretium quis, sem. pretium quis, sem. pretium quis, sem.
/ CTWD: 18mm / CTWD: 18mm / CTWD: 18mm
78
NEW PROCESS:
PMC MIX Drive
79
80
PMC-MIX ADVANTAGES
SEAM APPEARANCE
ripples like TIG
FREQUENCY
up to 15Hz EASIER ADJUSTMENT
ARC compared to SynchroPulse
stable arc also when robot/torch

position is changing
REDUCED HEAT INPUT
compared to Synchro Pulse
 better gap bridgability
81 Fronius International GmbH / Product Launch Perfect Welding 2015

PROCESS DIAGRAM
82
HIGHSPEED VIDEO
83
DIFFERENCE TO SYNCHOPULSE
/ PMC – MIX generate less heat input compared to synchropulse

/ PMC – MIX easier to adjust as „Synchropulse“
84
/ Only two parameters to configure the ripples of the weldseam
APPLICATIONS OF „PMC MIX“ FOR ROBACTA DRIVE
/ aluminium applications
/ seam appearance nearly like TIG
e.g. bicycle frames
/ flange weld
/ Instead of „CMT + Pulse“ is used
85
NEW PROCESS:
PMC MIX Push
86
APPLICATIONS OF „PMC MIX“ FOR PUSH SYSTEMS
87
88
/ PMC Mix with less heat input than SynchroPulse
/ Short arc process gives more stability in low power phase
/ Three new corrections
/ „Number of pulse cycles“ for the high power phase e.g. 10 up to 150 pulse cycles
/ „Time adjustment“ for the shortarc process e.g. 200ms up to 1,5 sec
/ „Power correction“ for the shortarc process e.g. ± 20%
/ Longer low power phase than PMC Mix Drive
/ Better penetration in low power phase
89
/ PMC Mix is a process combination of pulse arc and short arc welding process
This combines both the advantages of both welding processes
Stability in lower power process phase due to short arc and controlled
Heat input due to pulse arc in high process power phase
/ PMC Mix is used especially for welding in positions

For automated welding as well as for manual welding
Like for example ship building, steelwork,…
/ One of the big advantages is at vertical up welding. Due to the pulsing,

the pendular movement is not needed any more. What means, it is
possible to weld vertical up with a continuous leading up of the welding torch.
- Easier for the welder
- Easy to mechanize
90 - Faster welding speed due to smaller „a“ measure
1.2 Steel wire
18% CO2 82% Ar
PMC mix UP
/ vertical up welding without „weave motion“

/ simple to mechanize
/ vertical up seams smaller than a 5
91
92
93
NEW FUNCTION.
TEACH MODE
94
FUNCTION TEACHMODE FOR ROBACTA DRIVE
95
Thank you for your
attention
96
All information is without guarantee in spite of careful editing - liability excluded.
Intellectual property and copyright: all rights reserved. Copyright law and other laws protecting intellectual property apply to the content of this presentation and the documentation enclosed (including texts, pictures, graphics, animations
etc.) unless expressly indicated otherwise. It is not permitted to use, copy or alter the content of this presentation for private or commercial purposes without explicit consent of Fronius.

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TPS 270i C Pulse

TPS 320i C Pulse

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TPS 320i / 400i / 500i / 600i

TPS 320i / 400i / 500i / 600i PULSE

TPS 400i LSC Adv

Fronius International GmbH / Perfect Welding , Team Training / APP034 TPS/i

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Dodavač žice WF 25i

Gorionik & Šlauf paket

Hladnjak CU 1400i PRO /MC

Fronius International GmbH / Perfect Welding , Team Training / APP034 TPS/i

Fronius International GmbH / Perfect Welding , Team Training / APP034 TPS/i

Fronius International GmbH / Perfect Welding / TPS/i

/ WF25i Case D200 or Case D300

I-kit Kranski-transport VR 5000

I-kit Aluminijski bočni klizač VR 5000

I-kit mjerač protoka plina VR 5000

Kolica Trabant VR 5000

/ U-žljeb sa 4 kontaktne točke

1100 … Performanse hlađenja [W]

/ Brzo i jednostavno spajanje hladnjaka

Lijeva Desna bočna

Glavni Menu sa karuselom

PULSE PMC – Pulse Multi Control

21 Fronius International GmbH / Intelligent Revolution / 20.08.3013

/ LSC znači Low Spatter Control

/ Svojstva luka kratkog spoja: manja kontrola i više prskotina.

Preklopni spoj Kutni spoj Popuna & Završni prolaz

/ Jednolilčna karakteristika luka / Visoka stabilnost luka / Velika količina depozita

/ wfs: 6m/min (235ipm) / wfs: 6m/min (235ipm)

Vrste zavarenih spojeva

1mm 1mm 1mm

Postavka Dynamic u minus Postavka Dynamic na 0 Postavka Dynamic u plus

/ Povećan tlak luka / Srednji tlak luka / Manji tlak luka

Short arc vertical down LSC Short arc vertical up LSC

Solid Wire Ø 1,2mm (0.045”) Cellulose Electrode Ø 3,25mm (E6010)

/ Open root welding

/ Pravilno postavljanje kabela

Magnetska polja se poništavaju

Proces Induktivitet Stabilnost luka

/ Postavljanje kabela direktno utječe na induktivitet

/ Konfiguracija LSC CE / Konfiguracija LSC Advance CE

/ LSC Configuration 400-460V / LSC Advanced Configuration 400-460V

/ LSC Configuration MV / LSC Advanced Configuration MV

/ LSC Configuration 600V / LSC Advanced Configuration 600V

Povećana Stabilnost Luka

Stabilizator penetracije na OFF Stabilizator penetracije na ON

AL-Stab = 0 AL-Stab = 0.5 AL-Stab = 2

Result using Stabilizer Result using Stabilizer

Pulse PMC Universal PMC PCS

5mm 5mm 5mm

/ Synergic line: 2785 / Synergic line: 2850 / Synergic line: 2890

Std. universal Std. Dynamic LSC Univ.

5mm 5mm 5mm

/ Synergic line: 2566 / Synergic line: 2630 / Synergic line: 2765

Pulse PMC Universal PMC PCS

5mm 5mm 5mm

/ Synergic line: 2785 / Synergic line: 2850 / Synergic line: 2890

Std. Universal Std. Dynamic LSC Univ.

5mm 5mm 5mm

/ Synergic line: 2566 / Synergic line: 2630 / Synergic line: 2765